Flowmeter and Method

ABSTRACT

A flowmeter for detecting fluid flow rates in a pipe includes a tube having a channel disposed in the pipe through which fluid in the pipe flows. The flowmeter includes an upstream transducer in contact with the pipe and positioned so plane waves generated by the upstream transducer propagates through the channel. The flowmeter includes a downstream transducer in contact with the pipe and positioned so plane waves generated by the downstream transducer propagate through the channel and are received by the upstream transducer which produces an upstream transducer signal. The downstream transducer receives the plane waves from the upstream transducer and provides a downstream transducer signal. The flowmeter includes a controller in communication with the upstream and downstream transducers which calculate fluid flow rate from the upstream transducer signal and the downstream transducer signal. 
     A method for detecting fluid flow rates in a pipe.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/565,341 filed Aug. 2, 2012, now U.S. Pat. No. 8,806,734, which is adivisional of U.S. patent application Ser. No. 12/653,087 filed Dec. 8,2009, now U.S. Pat. No. 8,245,581 issued Aug. 21, 2012, all of which areincorporated by reference herein.

FIELD OF THE INVENTION

The present invention is related to a flowmeter for detecting fluid flowrates in a pipe having a tube with a channel disposed in the pipethrough which fluid in the pipe flows and plane waves generated by anupstream ultrasonic transducer and a downstream ultrasonic transducerpropagate. (As used herein, references to the “present invention” or“invention” relate to exemplary embodiments and not necessarily to everyembodiment encompassed by the appended claims.) More specifically, thepresent invention is related to a flowmeter for detecting fluid flowrates in a pipe having a tube with a channel disposed in the pipethrough which fluid in the pipe flows and plane waves generated by anupstream ultrasonic transducer and a downstream ultrasonic transducerpropagate, where the tube is made of a sound absorbing material so thatessentially all non-fluid paths of sound are absorbed.

BACKGROUND OF THE INVENTION

This section is intended to introduce the reader to various aspects ofthe art that may be related to various aspects of the present invention.The following discussion is intended to provide information tofacilitate a better understanding of the present invention. Accordingly,it should be understood that statements in the following discussion areto be read in this light, and not as admissions of prior art.

The current ultrasonic flow meter arrangement uses two transducers atopposing ends of a pipe where one is upstream from the fluid flow andother is downstream from the fluid flow, both transducers transmit andreceive signals. Each transducer generates plane waves into the fluidand surrounding pipe wall. The difference in transit times between theupstream and downstream signal is used to calculate the flow rate. Sincesound travels faster in the pipe wall than in the fluid medium, thereceiving transducer has noise because the sound enters the pipe andarrives at a time preceding the sound that travels in the liquid. Thenoise level is significant because it reduces the accuracy of the flowmeasurement and results in a poor or no measurement at low flow rates.

Furthermore, traditionally, polymers with scattering fillers (such asmetal or glass or microspheres) are used as backing masses forultrasonic transducers. The use of an attenuative backing mass improvesthe bandwidth of the transmitted ultrasound signal of a transducer byabsorbing the sound from the back side of the transducer and notallowing reflections to occur. Polymers with scattering fillers, it isbelieved, have never been used as pipe wall sound attenuators in the useof an ultrasonic transit time flow measurement.

BRIEF SUMMARY OF THE INVENTION

The present invention is applicable for measuring flow rates,particularly low flow rates, with ultrasonic transit time technology.The application is specifically applied to monitoring chemical fluidinjection in subsea oil wells. The invention is directed to the use of asound absorbing tube to direct the flow. This tube attenuates sound ofall acoustic paths except that through the fluid. This improvement makespossible a flow measurement at very low flow rates through very smallbore pipes.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

In the accompanying drawings, the preferred embodiment of the inventionand preferred methods of practicing the invention are illustrated inwhich:

FIG. 1 shows a flowmeter of the present invention.

FIG. 2 shows an acoustic signal path.

FIG. 3 shows a low flow meter arrangement.

FIG. 4 shows a demonstration of transit time flow meter performance—a4.5 mm diameter tube with 100 cSt Oil (3 Mhz Signal).

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings wherein like reference numerals refer tosimilar or identical parts throughout the several views, and morespecifically to FIGS. 1 and 3 thereof, there is shown a flowmeter 10 fordetecting fluid flow rates in a pipe 12. The flowmeter 10 comprises atube 14 having a channel disposed in the pipe 12 through which fluid inthe pipe 12 flows. The flowmeter 10 comprises an upstream ultrasonictransducer in contact with the pipe 12 and positioned in alignment withthe channel so plane waves generated by the upstream transducer 16propagate through the channel. The flowmeter 10 comprises a downstreamultrasonic transducer in contact with the pipe 12 and positioned soplane waves generated by the downstream transducer 18 propagate throughthe channel and are received by the upstream transducer 16 whichproduces an upstream transducer 16 signal. The downstream transducer 18receives the plane waves from the upstream transducer 16 and provides adownstream transducer 18 signal. The flowmeter 10 comprises a controller20 in communication with the upstream and downstream transducers 18which calculate fluid flow rate from the upstream transducer 16 signaland the downstream transducer 18 signal.

The tube 14 may be made of a sound absorbing material so thatessentially all non-fluid paths of sound are absorbed. The upstreamtransducer 16 and the downstream transducer 18 may extend through thepipe 12 wall and acoustically communicate with the pipe 12 interior, Thetube 14 may form a seal with the pipe 12 essentially preventing fluid inthe pipe 12 leaking around the tube 14.

The tube 14 may be made of a polymer filled with attenuative particles.The polymer may be either an epoxy, nylon, PTFE or PEEK(polyaryletheretherketone). The particles are either metal, glassmicrospheres, metal oxide or rubber having a size equal to or smallerthan the acoustic wavelength. The tube may have a length L and adiameter opening D such that under volume flow conditions where Q>0.2liters/hour, the tube dimensions L/D² are greater than 1385/meters whenC>1400 m/s.

The present invention pertains to a method for detecting fluid flowrates in a pipe 12. The method comprises the steps of flowing fluidthrough a channel of a tube 14 disposed in the pipe 12. There is thestep of generating plane waves by an upstream transducer 16 in contactwith the pipe 12 and positioned in alignment with the channel so theplane waves propagate through the channel and are received by adownstream transducer 18 which produces a downstream transducer 18signal. There is the step of generating plane waves by the downstreamtransducer 18 in contact with the pipe 12 and positioned so the planewaves propagate through the channel and are received by the upstreamtransducer 16 which produces an upstream transducer 16 signal. There isthe step of calculating with a controller 20 in communication with theupstream and downstream transducers 18 fluid flow rate from the upstreamtransducer 16 signal and the downstream transducer 18 signal.

The tube 14 can be made of a sound absorbing material and wherein thegenerating plane waves by the upstream transducer 16 step may includethe step of generating the plane waves by the upstream transducer 16 sothat essentially all non-fluid paths of sound are absorbed by the tube14, and wherein the generating plane waves by the downstream transducer18 step may include the step of generating the plane waves by thedownstream transducer 18 so that essentially all non-fluid paths ofsound are absorbed by the tube 14. The generating plane waves by theupstream transducer 16 step may include the step of generating the planewaves by the upstream transducer 16 which extends through the pipe 12wall and acoustically communicates with the pipe 12 interior, andwherein the generating plane waves by the downstream transducer 18 stepmay include the step of generating the plane waves by the downstreamtransducer 18 which extends through the pipe 12 wall and acousticallycommunicates with the pipe 12 interior. The tube 14 may form a seal withthe pipe 12 essentially preventing fluid in the pipe 12 leaking aroundthe tube 14.

In the operation of the invention, the current ultrasonic flow meterarrangement uses two wetted transducers at opposing ends of a tube 14 ina pipe 12 where one is upstream from the fluid flow and other isdownstream from the fluid flow, both transducers transmit and receivesignals (FIG. 1). The difference in transit times between the upstreamand downstream signal is used to calculate the flow rate. Eachtransducer generates plane waves into the fluid and surrounding pipe 12wall (FIG. 2). The propagation of the sound wave has a profile known asthe transducer beam profile.

${{For}\mspace{14mu} \Delta \; t} = {\frac{2{VL}}{C^{2}} = \frac{8\; {QL}}{\pi \; C^{2}D^{2}}}$

-   -   L: path length    -   C: speed of sound in fluid    -   V: fluid velocity    -   C>>V    -   Δt: t₂−t₁ transit time difference    -   Q: mass flow    -   D: diameter of opening

As the mass flow decreases so does the transit time difference betweenthe upstream and downstream flow. By increasing the length “L” of thetube 14 and decreasing the diameter opening “D” the effective Δt can beincreased such that Δt>0.1 ns, under low mass flow conditions theflowmeter 10 has to be designed such that the tube 14 dimensions

$\frac{L}{D^{2}}$

can measure a Q as low as 0.2 liters/hour since C is a constant.

For FIG. 1:

$t_{2} = \frac{L}{C - V}$

-   -   t₁: upstream transit time    -   t₂: downstream transit time    -   L: path length    -   C: speed of sound in fluid    -   V: fluid velocity

${t_{1} = {\frac{L}{C + V}\mspace{14mu} C}}\operatorname{>>}V$$V = {{\frac{C^{2}\Delta \; t}{2L}\mspace{14mu} \Delta \; t} = {\frac{2{VL}}{C^{2}} = \frac{8{QL}}{\pi \; C^{2}D^{2}}}}$Q = V ⋅ Area  Q:  Mass  Flow  D:  diameter  of  opening$V = {{\frac{Q}{A}\mspace{14mu} {Area}} = \frac{\pi \; D^{2}}{4}}$

In order to solve for the speed of sound in fluid and fluid velocity theupstream and downstream transit times need to be measured via acontroller 20. The controller 20 computes the transit time differencesbetween the upstream and downstream flow. The Δt is then used tocalculate the fluid velocity for a given flowmeter 10 length “L” for acalculated speed of sound “C”. Once the velocity “V” has been calculatedthen the Mass Flow Q can be determined since the area “A” of the fluidopening or pipe 12 is known.

For FIG. 2:

-   -   λ: wavelength    -   Nd: focal length

$\phi = {\sin^{- 1}\left( \frac{{.61}\; \lambda}{r} \right)}$

-   -   r: radius of the transducer

${Nd} = \frac{r^{2}}{\lambda}$

$\lambda = \frac{c}{f}$

When sound diverges at angle φ, it then propagates into pipe 12 wallwhich is received by the opposing transducer as noise.

-   -   f: frequency

Since sound travels faster in the solid pipe 12 or tube 14 wall than inthe fluid medium, the receiving transducer suffers from acoustic noisefrom the pipe 12/tube 14 acoustic paths. This acoustic noise arrives ata time preceding the sound that travels in the liquid since soundvelocities in the solid are higher than those in the fluid. This noiseis significant because it reduces the accuracy of the flow measurementand results in a poor or no measurement at low flow rates. The measureof the effect of this noise is signal to noise ratio.

In order to solve this problem, a tube 14 with acoustically attenuativeproperties is in inserted within the pipe 12 (FIG. 3). The acoustic tube14 has a small inner diameter and a large outer diameter. The opening inthe tube 14 acts as conduit for the fluid and the fluid path for sound,while the surrounding area acts as sound absorber. After the soundtravels through the conduit it begins to spread again but this has noeffect on the signal to noise ratio therefore the surrounding soundabsorber successfully disables the pipe 12 noise.

The tube 14 is made preferably of a polymer filled with attenuativeparticles, for example tungsten particles (mesh 200) with a certainvolume fraction up to 50%. The polymer can be for example epoxy, nylon,PTFE or PEEK but is not limited to these materials. The choice ofpolymer is dependent on the pressure rating of the application and itseffectiveness in working with the attenuative particles to attenuatesound. The filler can be any metal, metal oxide, or rubber with a smallmesh size, the lower the volume fraction of particle filler the higherthe acoustic attenuation. Once a cylinder is fabricated then it ismachined such that there is an inner diameter for fluid flow. The soundabsorbing tube 14 can be threaded on the OD; therefore, it screws intothe flowmeter 10. The sound absorbing tube 14 can be glued on the OD;therefore, it bonds into the flowmeter 10. The sound absorbing tube 14can either press fit or captured by clips or retainers.

Simple ultrasonic flow measurement tests have shown an improvement inthe signal to noise ratio at low flow rates. The experimental setupincluded 5 MHz frequency ultrasonic transducers separated a distance of4 inches. The tube 14 used had an inner diameter of ¼″ and outerdiameter of 1″. The tube 14 was made of epoxy with tungsten particlefiller. For test purposes olive oil was used since it has a similarviscosity to certain injection chemicals to be applied. It is noted thatthe higher the viscosity of the fluid, the more important the soundabsorbing properties become. Specifically, as the viscosity increases,the fluid path acoustic signal is attenuated and the signal to noiseratio decreases.

A flow rate of 1 liter/hour was measured and the signal to noise ratioimproved by 10 times using the attenuative tube 14. Flow rates as low as0.2 Liters/hour are readily achievable. Flow rates up to 90 liters/hourmay also be analyzed. The low flow meter enables a chemical injectionmetering valve to dispense corrosion preventing chemicals to the subseawell at a low flow rate. The low flow meter is being used for chemicalinjection, but it could also be used for any application requiring ameasurement at low flow rates. See FIG. 4 which shows a demonstration oftransit time flow meter performance—a 4.5 mm diameter tube with 100 cStOil (3 MHz Signal).

During ultrasound transmission any sound which propagates at an angleafter the transducer focal length is attenuated or absorbed within thesound absorber tube 14 walls. This allows a line of sight ultrasoundsignal to be received uninhibited from any other acoustic noise source.As a result the signal to noise ratio is greatly improved therebyenabling ultrasonic transit time flow measurements at very low flowrates that were not possible before since the SNR increased 10 timesfold. This invention will be used in a low flow meter for monitoringfluid injection in subsea oil wells.

Although the invention has been described in detail in the foregoingembodiments for the purpose of illustration, it is to be understood thatsuch detail is solely for that purpose and that variations can be madetherein by those skilled in the art without departing from the spiritand scope of the invention except as it may be described by thefollowing claims.

1. A flowmeter for detecting fluid flow rates in a pipe comprising: atube having a channel disposed in the pipe through which fluid in thepipe flows; an upstream ultrasonic transducer in contact with the pipeand positioned and positioned in alignment with the channel so planewaves generated by the upstream transducer propagates through thechannel; a downstream ultrasonic transducer in contact with the pipe andpositioned and positioned in alignment with the channel so plane wavesgenerated by the downstream transducer propagate through the channel andare received by the upstream transducer which produces an upstreamtransducer signal, the downstream transducer receiving the plane wavesfrom the upstream transducer and providing a downstream transducersignal; and a controller in communication with the upstream anddownstream transducers which calculate fluid flow rate from the upstreamtransducer signal and the downstream transducer signal.
 2. The flowmeteras described in claim 1 wherein the tube is made of a sound absorbingmaterial so that essentially all non-fluid paths of sound are absorbed.3. The flowmeter as described in claim 2 wherein the upstream transducerand the downstream transducer extend through the pipe wall andacoustically communicate with the pipe interior.
 4. The flowmeter asdescribed in claim 3 wherein the tube forms a seal with the pipeessentially preventing fluid in the pipe leaking around the tube.
 5. Theflowmeter as described in claim 4 wherein the tube is made of a polymerfilled with attenuative particles.
 6. The flowmeter as described inclaim 5 wherein the polymer is either an epoxy, nylon, PTFE or PEEK. 7.The flowmeter as described in claim 6 wherein the particles are eithermetal, metal oxide, glass microspheres or rubber having a mesh size lessor equal to the acoustic wavelength.
 8. The flowmeter as described inclaim 6 wherein the tube has a length L and a diameter opening D suchthat under volume flow conditions where Q>0.2 liters/hour, the tubedimensions L/D² are greater than 1385/meters when C>1400 m/s.
 9. Amethod for detecting fluid flow rates in a pipe comprising the steps of:flowing fluid through a channel of a tube disposed in the pipe;generating plane waves by an upstream ultrasonic transducer in contactwith the pipe and positioned in alignment with the channel so the planewaves propagate through the channel and are received by a downstreamtransducer which produces a downstream transducer signal; generatingplane waves by the downstream ultrasonic transducer in contact with thepipe and positioned in alignment with the channel so the plane wavespropagate through the channel and are received by the upstreamtransducer which produces an upstream transducer signal; and calculatingwith a controller in communication with the upstream and downstreamtransducers fluid flow rate from the upstream transducer signal and thedownstream transducer signal.
 10. The method as described in claim 9wherein the tube is made of a sound absorbing material and wherein thegenerating plane waves by the upstream transducer step includes the stepof generating the plane waves by the upstream transducer so thatessentially all non-fluid paths of sound are absorbed by the tube, andwherein the generating plane waves by the downstream transducer stepincludes the step of generating the plane waves by the downstreamtransducer so that essentially all non-fluid paths of sound are absorbedby the tube.
 11. The method as described in claim 10 wherein thegenerating plane waves by the upstream transducer step includes the stepof generating the plane waves by the upstream transducer which extendsthrough the pipe wall and acoustically communicates with the pipeinterior, and wherein the generating plane waves by the downstreamtransducer step includes the step of generating the plane waves by thedownstream transducer which extends through the pipe wall andacoustically communicates with the pipe interior.
 12. The method asdescribed in claim 11 wherein the tube forms a seal with the pipeessentially preventing fluid in the pipe leaking around the tube. 13.The method as described in claim 12 wherein the tube has a length L anda diameter opening D such that under volume flow conditions where Q>0.2liters/hour, the tube dimensions L/D² are greater than 1385/meters whenC>1400 m/s.